Chapter 1 Routine maintenance and servicing

Bodywork and fittings 11•715.2 Radiator grille slot fixing holesrequired on service replacement bumpers(dimensions given in mm - see text)16.2 Front bumper-to-wheelarch retainingscrews (arrowed)16.3 Front bumper retaining nut locationRefitting12 To refit, engage the wheelarch mouldinginto the clamp, align the moulding studs withtheir wheelarch locations, then position themoulding onto the wheelarch. Refit the fourfixing nuts to secure the upper part of themoulding, but do not fully tighten.13 Refit the plastic stud, but do not fullytighten.14 Offer the sill extension moulding to itslocation, centring it between the front and rearwheelarches to check the rear wheelarchmoulding alignment. Adjust the alignment asnecessary.15 With the rear wheelarch mouldingalignment correct, fully tighten the fixing nutsand the plastic stud.16 Insert the rivet to secure the forward endof the moulding.17 Refit the sill extension moulding, asdescribed in Section 12.15 Wind deflector/radiator grilleslat - removal and refitting 1Removal1 The radiator grille slat is secured to the frontbumper by three clips. To remove it, simplyslide the clips rearwards to release them, thenwithdraw the grille slat from its bumperlocating holes.2 If fitting a radiator grille slat to a servicereplacement bumper, two 8.0 mm diameterholes will need to be drilled to accommodatethe grille slat end fixings and, in addition, a12.0 mm square central hole must also bemade (see illustration).Refitting3 Refitting is a reversal of the removalprocedure.16 Bumpers -removal and refitting 2Front bumperRemoval1 Open the bonnet and disconnect theauxiliary light multi-plugs, as applicable.2 Remove the bumper retaining screws fromthe leading edge of the wheelarch flanges,then ease the bumper away from itswheelarch location (see illustration).3 Remove the bumper retaining nuts from thereverse side of the body panel beneath theheadlights (see illustration) then, with thehelp of an assistant, remove the bumperassembly from the vehicle.Refitting4 To refit, (again with assistance) position thebumper onto its panel, ensuring that theretaining studs pass through their bodylocations, and that its ends align to thewheelarches.5 Loosely refit the bumper retaining nuts andthe bumper-to-wheelarch retaining screws.6 Ensuring that the bumper is level, and thatan even gap is maintained between it andsurrounding body panels, tighten the retainingnuts to the specified torque.7 Tighten the bumper to wheelarch retainingscrews.8 Refit the auxiliary light multi-plugs, asapplicable.9 The alignment of light units requires the useof optical beam setting equipment so, whereapplicable, entrust this task to a Ford dealer.Rear bumper (all models exceptCourier)Removal10 Using a screwdriver or similar tool, priseup the number plate light unit from therear bumper, being careful not to damage thebumper. Disconnect the bulbholder andremove from the bumper.11 Remove the bumper-to-wheelarchretaining screws as necessary (seeillustration).12 Open the tailgate then, using a suitablysizedsocket, remove the bumper retainingnuts located inside the luggage compartment(see illustration).13 Carefully remove the bumper from itslocation.Refitting14 To refit, first align the bumper to thevehicle body, ensuring that the ends engagecorrectly at the wheelarches and the securingstuds enter through the body panel.15 Refit the bumper-to-wheelarch inner rimretaining screws, as applicable.16 Refit the bumper retaining nuts, tighteningto the specified torque.17 Reconnect the number plate lightbulbholder, then refit the light unit to thebumper.Rear bumper (Courier models)Removal18 Unscrew the two screws securing eachbumper end moulding to its respective wheel1116.11 Rear bumper-to-wheelarch retainingscrews (arrowed)16.12 Rear bumper retaining nut locations(arrowed)1595Ford Fiesta Remake